Hurricane Maria forces Parknet to Pivot, Gigabot Lowers Risk

Antonio Ramos takes a deep breath. “It was really depressing.”

A native Puerto Rican, he was living in San Juan when Hurricane Maria hit. He described the sentiment on the island when the storm was forecasted: Irma had just passed by with little effect, and the general feeling was that Maria would also spare them. The island is used to storms, he explains, and they usually bounced back after big ones in a couple weeks.

But this one turned out to be different.

He remembers seeing the radar images of the vastness of the tempest bearing down on them, their island dwarfed next to it. The dire situation quickly became apparent. Antonio recalls his reaction: “Okay, we’re screwed.”

It wasn’t just Antonio that had to weather the storm – he had a company to tend to as well.

From Capstone Project to Company

Antonio and his cofounder, Alan Lopez, started Parknet when they were still engineering students in university. They used the idea for their Capstone Project, building a controller that could connect to the Internet using Wi-Fi or SIM cards and control a boom barrier or electromagnetic gate – “really anything that could be activated,” Antonio explains.

They approached a local company with their idea, proposing to them that they could reprogram their controller in real time.

“They actually challenged us,” recounts Antonio. “They told us, ‘Hey, that can’t be done.’” The company said the only way to reprogram it was to go into a computer, use their software, and reprogram the whole controller.

Antonio didn’t balk. “I told them, ‘No, we can actually hack your controller.’” The company didn’t budge.

“So, it was a challenge,” says Antonio. “And challenge accepted. Something that we’ve learned is that you never challenge an engineer and say that they can’t do something, because they will do it.”

Six months later, Antonio and Alan demoed for the company their “unhackable” controller working as they had originally pitched. Parknet was born.

Maria's Arrival

Parknet makes cloud-based controlled access systems which provide facility administrators the ability to control access points – think entry doors or parking gates – in real-time, through the use of a web-based app accessible from any device with an internet connection.

Antonio and Alan explored different routes for how to market their system in Puerto Rico.

“At first, we wanted to use it for a parking lot payment system. But we found a bit of resistance here from the parking administrators,” Alan explains. They shifted their focus to gated communities and apartment complexes.

They joined the Generation Four cohort of Puerto Rican incubator program Parallel18 in August. And then, in September, Maria arrived.

“After the hurricane, we had no cell phone communication, we had no Internet, no power. It was really depressing,” Antonio recounts. “Our business needs Internet. It’s an Internet of Things device, so it needs Internet to operate and it needs power. So we were kind of stuck there.”

They pivoted yet again, strategizing how to stay afloat and retain their employees.

“We had to survive,” Antonio says. “The sales cycle for gated communities and apartment complexes can be from four to six months. It takes a lot of time and a lot of meetings and convincing.” But they found that with commercial spaces, the process was faster. “We started selling to co-working places and offices.” One such customer is Parallel18 itself.

Antonio stopped paying himself in order to keep his team on payroll. “We were in survival mode,” he explains. He began working in generator repairs, a service in high demand on the island following Maria.

They weathered the monster storm and its lingering aftermath, and several months later the company was back on its feet. As Parknet started demanding more from Antonio, he wrapped up his generator repair work and went back to it full time.

3D Printing Before Moving to Manufacturing

In the Parallel18 program, Parknet crossed paths with re:3D.

They began using Gigabot to 3D print enclosures for their printed circuit boards, or PCBs. “We can build a box in like, two hours, and we can test it before we send it to the manufacturer,” Antonio explains. “The manufacturer had a minimum of 10 boxes, and if it didn’t work correctly, we were going to waste 10 boxes.”

Once they finalized the enclosure design, they moved to a sheet metal forming process, but they continued to turn back to Gigabot for custom requests. “One of the advantages is that we can offer a customer a custom design,” Antonio says. “If they want a diamond shaped scanner, we can build it for them. If they want it embedded into a gypsum board, we can also do that.”

One Parknet customer in San Juan who has requested a diamond-shaped scanner is El Almacén, a speakeasy-style bar tucked away just off the buzzing square of La Placita.

They’re using Parknet’s technology to text message patrons digital keys and grant them entry to the bar with the swipe of a phone. The door unlocks and the e-key-holder descends into an old-timey themed lounge.

It also gives the bar the marketing opportunity to track and quantify their marketing. They can compare how many people the text message key was sent to and how many people used it, rather than their old method, which was a post on their Facebook page with the password for the night. There is also the location-based aspect of it – if a patron gets within a certain radius of the bar, their phone will remind them that they have a key to the nearby locale.

Moving Forward Post-Maria

It’s just past the one year anniversary of Hurricane Maria’s landfall.

Puerto Rico has recovered fairly well given the incredible destruction of the storm. The land itself looks lush and green, and the people I spoke with are propelled by a resilient spirit and a desire to rebuild and strengthen their island for the future.

Antonio is one of those very people. Parknet came out the other side of Maria arguably a stronger company, with more applications and a wider customer base than he and Alan had originally imagined. It’s been a big cycle for them that has taken them through multiple major pivots in the company’s lifespan.

After the trials of Maria, Parknet is now focused back on gated communities and apartment complexes and is ready to tackle their original vision of parking lots.

Learn more about Parknet: https://www.linkedin.com/company/parknet.pr/about/

Learn more about Parallel18: https://www.parallel18.com/

Morgan Hamel

Blog Post Author

Skating on Water Bottles

This post is a follow-up to this one on the Gigabot X pellet printer. If you haven’t checked it out or watched the video, start there!

We know you’ve been dying to know what on Earth our Gigabot X pellet printer prototype was printing in the last update video, so we’re here to deliver!

Without further ado, the reveal.

The slick design was dreamt and drawn up by one of the students working on Gigabot X material validation at Michigan Tech University. Our team was really excited about the idea of printing the board using one of our favorite new materials we’ve been testing: recycled PET.

Giving water bottles a second lease on life as a fun, functional object? As Robert put it, “You know, we had to do it.”

We went through a few trials of the board, snapping a couple of the earlier prints due to the design being a little too thin or not printing it with enough infill. We thickened up the design and increased the infill percentage to make the board a little sturdier, leaving us with a roughly six and a half hour, five pound print.

After popping on some trucks and wheels, re:3D Engineer & Resident Skater Jeric Bautista took the board for a spin behind the Houston office.

Jeric gave the board his stamp of approval. “The skateboard was really fun to use,” he said. “It was smooth to ride and the PET made it nice and springy, which is similar to normal skateboards. Seeing firsthand the functionality of recycled plastic was definitely very cool.”
 
Keeping plastic bottles out of landfills by giving them a new life as functional objects? That’s something we can roll with.

Morgan Hamel

Blog Post Author

Grand Opening of the NYU Tandon School of Engineering Veterans Future Lab

On Monday of this week I had the privilege of attending the Grand Opening of the NYU Tandon School of Engineering Veterans Future Lab in Brooklyn, New York.

A very special lineup of speakers graced the event, including New York State Lieutenant Governor Kathy Hochul, Dean of Engineering at NYU Katepalli Sreenivasan, New York State Assemblyman Joseph Lentol, Barclays Group Chief Executive Officer Jes Staley, and one of the the engineering school’s namesakes, business-leader and humanitarian Chandrika Tandon.

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Housed in Industry City on Brooklyn’s “Innovation Coastline,” the lab will be an early-stage startup incubator for United States military veterans.

More than a third of all returning military veterans have entrepreneurial ambitions, speakers at the event remarked, but just under 5% launch their own businesses, according to the Bureau of Labor Statistics. With some 18 million veterans in the country, that’s a lot of unrealized business ideas.

Lieutenant Governor Kathy Hochul told a story about a moment that left a profound impression on her on a visit she made to an American military base in Afghanistan. Sitting around a table with a group of soldiers, she asked them about their greatest fears. And in that tent in the barren, almost lunarscape-esque terrain of Afghanistan, in the heart of Taliban territory, the soldiers’ response stunned her. They were worried about finding a job when they returned home.

The Veterans Future Lab addresses exactly this fear.

The goal of the program is to provide business support and mentorship to a group of people who have given so much to serve their country, to enable them to be successful in this next mission in their lives.

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With their first round of 15 companies starting in January, the program will offer participants 12 months of incubation, mentorship with New York City industry professionals and NYU faculty, and free legal services, among many more benefits.

One of the other perks of the program is the makerspace.

The businesses will have access to a bona fide buffet of prototyping equipment, from laser jets to water jets, injection machines to sewing machines, and – you guessed it – a Gigabot (among a list of other 3D printers).

As a veteran-owned company ourselves, we couldn’t be more excited to have a Gigabot available to the participants.

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Split between the NYU Tandon School of Engineering Makerspace in Downtown Brooklyn and the Veterans Future Lab offices in Industry City, any physical design and prototyping needs the entrepreneurs may have are covered from all angles.

A big deal for not only veterans but also the city and state of New York as a whole, the lab was made possible with the support of Barclays and the Empire State Development Corporation.

As Lieutenant Governor Hochul put it, “This is a very good day in the state of New York.”

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Morgan Hamel

Blog Post Author

THE GIGAPRIZE: 2016

I’m going to be forthcoming in this introduction and tell you that I have no background in 3D printing. In fact, working with the community during this year’s Gigabot Giveaway was my initiation into this world and network, and it has been nothing short of inspiring. My name is Beth Eanelli. You may know me as the community manager of the New Year’s Gigaprize: 2016 and I possibly sent you an email or asked to use one of your photos in a social media post.

As I mentioned, this was my introduction into 3D Printing, and I have been simultaneously humbled and overwhelmed by the innovation in the field. I had heard of 3D printing, read about it in magazines and articles, but as I was graduating University, I remember the first 3D printer coming to the Engineering Department, but I never had a chance to see the machine, or to watch it come to life.

My background is in public health and international development and I have dabbled in social impact, though never in the tech realm. I returned just in time for the holidays in 2015 after spending two years living and working as a health volunteer with the Peace Corps in a little country called The Gambia. The village I lived had no electricity and no running water, and health issues like Malaria and diarrhea still run rampant. In short, there were minimal resources and with the capital being across the country and transit towns having sporadic electricity and no consistency with products sold, managing projects and creating programs required constant rescheduling and a lesson in being a true MacGyver.

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The first time I met Samantha was at Unreasonable Impact, a program created with Barclays, which brings together entrepreneurs working towards social impact and change to build community, create jobs and help the entrepreneurs maximize their influence (blog to follow). In her introduction to re:3D, Samantha described the printers as having the ability to be mini factories in countries with little to no resources. Having seen the possibilities of what 3D printers could bring to communities such as the one I lived in, I was hooked, and Samantha and I spoke at length about what re:3D had and continues to accomplish. I imagined my community with a 3D printer, the nearest town with continuous access to a makerspace, and couldn’t believe this was a reality in some places because of re:3D. I learned of re:3D’s 1 Gigabot 3D printer donation for 100 sales during one of many conversations with Samantha and we connected right after the program. Shortly afterwards, I was asked to be the 2016 Community Manager for what was formally called The Great Big Gigabot Giveaway, renamed the Gigaprize due to Unreasonable mentor feedback that the opportunity should not be framed as a handout, rather recognition for global citizens doing extraordinary things to improve society.

I’m going to be honest and tell you that I watched each Giveaway entry video with an open jaw. And while many of you know that 3D printers can be used to print prostheses and create Makerspaces, I was learning along the way, consumed by the novelty. Some of our Gigaprize: 2016 applicants are impacting their communities by printing prostheses for low income families, using plastic waste to create clean energy, using makerspaces as a learning tool in schools and libraries and to keep students in school. There are entrepreneurs among us using plastic bottle tops as filament and creating jobs for those who are unemployed in the industry. Each applicant is a catalyst, an innovator and an inspiration and I am looking forward to the chance to see what everyone continues to do.

The most difficult part of the Giveaway was choosing just one winner to receive a Gigabot 3+ kit. Each person and group is contributing to their community in a profound way, so choosing just one entry isn’t easy. Emergency Floor, the winner this year, has an amazing story. They’re using the Gigabot to prototype flooring to be placed in refugee camps, providing refugees living in these camps warmer, safer and more hygienic. Amazing, right?

I also want to express my gratitude to the judges who helped us make this difficult decision, and brought their vast knowledge and range of expertise to the table. We could not have made this Gigabot giveaway possible without each of these individuals.

Lastly, I want to express my gratitude to the applicants and the 3D printing community for your ideas and innovation, your drive and passion, and for allowing me insight into this world. I also want to that the thousands that voted to share their support for such phenomenal idea. If you didn’t have a chance to watch the entries as they were live, you can still do so here. Want be introduced to one the amazing applicants? Feel free to send me a request!

Happy Printing!

~Beth

  • beth@re3d.org

PS- you can be the first to hear about Gigaprize : 2017 by signing up for the re:3D newsletter. Simply enter your email at the bottom of re3d.org 🙂

Beth Eanelli

Blog Post Author

Pitching for a Circular Economy: Why We Went to Hello Tomorrow in Paris

With the momentum of the Bunker Austin win behind us, Matthew & I flew to Paris and grudgingly paid the shipping for Gigabot to meet us in the gamble that either we would either 1) Get a selfie with Mr. Bloomberg (and much needed press) 2) meet someone willing to cover the bond & buy the ‘bot in France, or 3) we’d win our pitching track & return net positive.

It was a huge risk that our company really couldn’t afford in addition to our discounted flights and a shared hotel room (thankfully Matthew has a very supportive girlfriend with access to deals!). But as Matthew & I firmly believe printing from reclaimed plastics takes an ecosystem of problem solvers, which frankly needs more support, we felt that we had to attend once we were notified that we were pitching finalists.

We also were also intrigued by the premise of Hello Tomorrow, which unites technologists, academics, and corporations to solve the grand challenges facing humanity. 3D printing from trash appeared to be a perfect fit, and Gigabot had to be there. With the promise that we would print a kickass logo during the event, the incredibly kind Hello Tomorrow staff agreed to find space for Gigabot.

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Matthew arrived in Paris first from Houston, and greeted the oversized crate while I gave a talk on the social potential of 3D printing at Singularity University in effort to be considered as a speaker and then flew out from San Francisco.

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As we had witnessed at other events this winter, Gigabot arrived in perfect condition & was up & printing without any calibration. Jet lagged but determined to give it our all, we stayed up late practicing for the pitch competition the next day.

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The day kicked off with an outstanding keynote by Imogen Heap, who demoed her novel gloves to give more dimension to sound. Afterwards, we were humbled when she visited Gigabot and mused with us re: the intersections of community, technology & creativity. We (err….I) shamelessly asked to take a pic in return for a print.

Matthew unfortunately had caught a terrible cold from the travel & lost his voice, but powered through the day, ensuring Gigabot was tended to, I ate some food and we were set up for success at the competition.  We weren’t the only team committed to (or perhaps delusional about) our cause. The other startups were just as hungry to further their passion by building connections with other attendees, and meet corporations in order to foster partnerships. Even the Hello Tomorrow staff exemplified commitment to curating an ecosystem of problem solvers & pioneers, with a teammate receiving a Hello Tomorrow tattoo on stage live!

After witnessing one of the other finalists, Tridom, bring their impressively large robot to the stage, we seized the opportunity to roll Gigabot over as well, leaving the poor Hello Tomorrow staff with little space, and lengthy power chords to manage. However it was worth the inconvenience as our respective machines found love at first print & the selfies of Gigabot & Madeline were adorable.

Tensions mounted as each co-founder took the stage and presented the benefits our ideas offer society. The competition was fierce. Each company had significant traction, an impressive technology, and solid teams. Further adding to my nervousness was the realization that not only was this strongest cohort we had ever pitched against, but the judges were tough!  With Matthew manning Gigabot, I stumbled through slides & questioning. The judges challenged the market for 3D printing as whole as well as the profitability of printing from waste & thus eliminating the feedstock from what largely is a blade & razor model today. While I could certainly have done better, I did my best to build upon lessons learned from Atech in Aruba. I shared the promise of the growing industrial 3D printer segment, the opportunities to increase the market by enabling more people to fabricate onsite, and upside that direct drive pellet extrusion expands the library of printable materials while decreasing print times. Stepping off the stage I was sweaty, shaky, and confident we had lost. I apologized to Matthew, congratulated the team I thought had won and set our sights on the meetings we had arranged with L’Oreal, Michelin, and Airbus.

The afternoon flew by. We gave out all of the flyers we brought, and pitched several blue chip companies to give us access to their post-manufacturing waste. Gigabot had a blast 3D printing Hello Tomorrow logos for the staff & we found that while we likely hadn’t won our track, an unexpected gain from the event was that we had found our tribe.

The attendees were just like us: problem solvers spanning hard science, technology & impact. We met nonprofits such Claire from MSF (Doctors Without Borders) and academics from around the world that challenged us with their questions & feedback. Aside from the criticism we fielded from the pitch judges, we found the Hello Tomorrow community truly understood our vision & was incredibly supportive. Our only regret from the event was not having more time & resources to stay in Europe with Gigabot to follow-up on the multiple insightful conversations we had (or in Matthew’s case had pantomimed).

Tired, but encouraged & full of great French cuisine we caught a few more hours of sleep and dug out any remaining flyers we could scrounge up for a possible meeting with Mr. Bloomberg the following morning. We also stole an hour to sample French food- my taste buds were blown away!

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Meeting the former mayor of NY turned out to be a challenge as he was a popular man, and despite our best efforts we were unable to wrangle a selfie. We did however manage to meet a number of amazing people and took the time to visit the other exhibit booths. Before we knew it, the time had come to join the audience at the big stage and learn who had won the event.

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Coincidentally Matthew & I ended up sitting next to the team from Haelixa, which I was convinced had won. We argued about who was about to take home 15K euros until the programming began, and our track was announced first. To my utter surprise our name was called, and I wished I had taken the time to touch up my makeup, & brush my exhibit – day hair & coffee stained teeth while stumbling over legs and the sea of people between us & the stage.

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I arrived on stage with watery eyes and speechless as we received a hug & trophy from Airbus. You can imagine my consternation when I was then handed a microphone and told we had the next two minutes to pitch two rows of judges for 100K. Feeling ill prepared, I gave everything I had left in an enthusiastic and emotional appeal. While 15K would fund our prototype within a year, 100K could bring what we see as inherently right to commercialization. I did my best and knew that while willing the Grand Prize was a long shot, I was humbled to share our passion with such an amazing group. I also secretly hoped that Michael Bloomberg was watching from the sidelines and would offer our much sought after selfie.

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The best part of the night however, was backstage. As each other track winner joined us, we were blown away by their technologies and the awesomeness of each team. We also noted a curious fact: half of the track winners were pitched by females and/or also came from gender co-lead teams like us. We quickly assembled a cheering squad to celebrate the other winners as they joined us backstage and sponsor Chivas ensured there were plenty of drinks for the multiple toasts that ensued.

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After all had joined, we headed out to join a big band for the announcement of the Grand Prize winner, Lilium. Although the money would have provided what we desperately need to scale our vision to 3D print from waste globally, we were thrilled for their team!

We joined Gigabot & all for the after party and then rushed to pack up Gigabot before security threw us out.

The next day we caught a train and headed outside of Paris to meet a local Gigabot owner. At re:3D we try to visit customers when on the road as it not only provides valuable business intelligence but also is an incredibly rewarding opportunity to connect with the customers personally. We had a blast, and were super honored when they blessed us with a guided tour of the city on the way home and drove us to the Eiffel Tower. We couldn’t go up the monument due to the tools in our backpack, but we were fortunate to walk around the legs and stare into the impressive infrastructure for several minutes.

After pausing to reflect on the engineering & creativity above us, we grabbed dinner & prepped to leave.

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On the flight home my mind was filled with lights, relationships, and next steps. To all who made Hello Tomorrow and my first trip to France a success: thank you. Thank you for believing in bootstrapped underdogs, and for giving us a platform & resources to make the impossible slightly more tangible!

Happy Printing!

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Samantha snabes

Blog Post Author

@samanthasnabes

samantha@re3d.org

Improving Your Manufacturing Equipment with Gigabot

Below is Gigamachinist Steve Johnson’s second blog on 3D printing for re:3D’s Gigabot fabrication shop.

Improving Your Manufacturing Equipment with Gigabot

by Steve Johnson

Sometimes, you have a product that works, but there is a way to improve it to make it work better.

A few months back, we added a 4th axis rotary table to our mill at re:3D. It has allowed us to begin to capitalize on the full milling envelope of our machine, allowing us to mill as much as 8 times more parts per program cycle, and reduced the need for multiple operations on some parts.

We quickly found a weak spot in our rotary table though. The table was designed without any seals to prevent shavings from entering the gearbox. As a result, we have had to disassemble the rotary table twice now in order to clean out aluminum shavings that had bound up in the worm gear. We decided this time, that we needed to find a solution for this issue, to keep our mill up and running longer between needed maintenance.

Once we had the rotary table apart, we found the area where the shaving were getting into the gearbox. There is a groove in the back of the table section, and a boss on the rotary body that rides inside the groove. But the fit between the two, once assembled, is very loose, and will allow anything smaller than .1 of an inch to pass through. Obviously we needed some type of o-ring, or gasket in order to seal this gap, without creating unwanted friction.

A few quick measurements, and Matthew headed to the computer to create a short profile on Solidworks, that would fill the gap. Using Ninja semi-flex filament from www.ninjatech.com, we made a first print of that profile on Gigabot, and took it to the shop to test fit. It was a little tight, so back to the computer to adjust a couple dimensions, and another short profile print. Once we had the right fit, we revolved the profile into a full circle on Solidworks, and 15 minutes later, we had a custom made flexible gasket that seals the rotary table from chips without creating drag on the axis motor.

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We found a problem. We imagined a solution. And with Gigabot, we made it a reality today.

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Now we are back up and running so that we can manufacture the parts for YOUR new Gigabot.

Happy Printing!

Steve Johnson

Blog Post Author

The Pros & Cons(iderations) of Toilet-sized 3D Printing

3D printing large objects is a very rewarding experience; it is also an introduction to a magnified set of challenges that a user will face when designing and realizing his or her prints. To keep things simple, we’ll review some of the pros and cons of large-scale printing in a list format.

Pros:

Human Scale

The driving force behind Gigabot being so large was printing objects at a Human Scale. But what exactly does that mean? In our view, Human Scale means items that are sized to be useful and helpful in everyday life. An example of this is a compostable toilet, which has been one of the prints that we’ve always considered to be of utmost importance. At this scale, furniture, as seen below, can be printed. Tables, lamps, and even low cost-prosthetics all fit into the idea of Human Scale Prints.

Practical Functionality

In addition to the Human Scale benefit of large format 3D printing, Practical Functionality is also a key aspect. For example, to scale models of engine parts, hand-held devices, toys, newly designed mechanical components, and so many more items are useful for sales and visualization purposes. When the model is smaller than the real-world equivalent however, it is difficult to fully appreciate tolerances, and nuances in design. With a large volume for printing, items that are full sized can be fabricated and used for fit-checks, actual function, and testing purposes.

Strength

With larger prints that are a single object, greater strength can be achieved. This is due to the perimeters encapsulating the entire object and passing loads throughout without disruptions in the path. The Infill that is inside also assists in taking the load and spreading it through the entire print and thus reducing stress concentrations. This allows prints to be very strong in compression, and to a lesser extent, tension. Depending on the infill percentages used on a print, the forces necessary to cause damage may be well in excess of what an average adult could exert.

No Assembly Required

There are many instances where 3D printed objects are glued, melted, or mechanically held together to form larger pieces. One of the wonderful characteristics of having the ability to print in large format is that pre- and post-processes such as those can be eliminated. When printing smaller pieces for an item that will be assembled, there may need to be design work to add pegs and keys assist pieces in locking together. On the backend, using adhesives and other methods are time consuming and not always simple. The ability to fabricate a large object in one go helps to simplify the manufacturing process and save time.

Expanded Creativity and Capability

Art is on area where 3D printing shines when scale in involved. So many more beautiful details can be expressed or replicated in a piece that is large. For example, there have been several artists who have made pieces over 20 feet long by incorporating 3D printing into their skillset. Sculptures of dinosaurs with incredible skin detail have been cast by a lost wax process after using 3D printed pieces as the base of the work. (A process, I like to call Lost Plastic instead!) Full size busts of persons have been printed as well as spaceship simulators and functional robots. The possibilities for creating new items is endless!

Cons(iderations)

Importance of Bed Leveling

Keeping the bed of a 3D printer level is one of the most important aspects of getting a piece to be made well. Without proper leveling, corners may warp, objects may not stick to bed, and objects may have poor surface quality. This is true for any size printer, but it becomes more important when a larger surface is used. Imagine a 5 degree angle from one point of a bed plate to the other. If the bed plate was 15 inches long, the difference in height on the other side of the bed plate would be 1.31 inches. If the bed plate was 30 inches long, that vertical differential is now double at 2.62 inches which is much more dramatic. It demonstrates the importance of minimizing any angles and ensuring that the bed plate is as flat as possible

Learning New Slicing Profiles

One of the most complicated parts of 3D printing is learning about all the settings that are involved with making an object. I’ve listed several here, although there are many more that can be adjusted for any print. Learning how to adjust these setting for new sizes takes a little bit of practice and can make all the difference between a nice print and a great print.

Number of Solid Bottom and Top Layers

With smaller prints the number of Solid Bottom and Top Layers is typically two or three, depending on the infill percentage. Usually a decent number is about 15% which gives a nice structure inside the print and means that the solid layers will not sag very much when being printed on the infill. With larger prints, however, infills can at times be down to 1-2% leaving up to an inch between supporting infill. The first solid layer will usually droop between these sections and the next layers may not have good finishes. Increasing the number of solid layers will allow the print to have a much nicer finish as the bottom layers support the ones after them.

Number of Perimeters

The number of perimeters typically also increase with an increase in print size. Having this number go up allows a print to be stronger and more rigid. It also allows for more surface area for the higher layers to print on. Where there are steep angles, this helps to provide a betters surface finish.

Infill Density

As mentioned before, infill density typically decreases when print size increases. This help in several ways: it reduces the final weight of the print, reduces the amount of material used, and reduces the print time. It is also not necessary to have such a high infill when the number of perimeters and solid layers has gone up, as much those characteristics help to strengthen the piece.

Layer Height

Layer height is one of the settings that is changed when trying to affect the surface finish. However, it can also be used to decrease print times. Doing so will lower the print quality, but not by a noticeable amount. Typically most printing is set at a default layer height of 300 microns which produces smooth surface finishes, but the layers can be seen. Most folks don’t mind this finish as it is a nice compromise between time and quality. However, for rough prototyping, or surface finishes that will be post-process, the layer height can be increased to save time.

Support Criteria

Since overhangs may be much more pronounced in larger models, there will be new instances where support may be needed where it was not needed in a smaller model. Luckily, most slicing software is smart enough to calculate where support is necessary, so this does not impact the user much, but it is an aspect to take into consideration when looking at material usage and print times.

Much more Support

As mentioned previously, there may be instances may be necessary on larger models where it may not have been necessary on the same smaller model. For this reason, much more support is typically seen on larger models. Not only for features, but also due to the size of the print itself. A very tall print with many overhangs would require significant support structure to make sure it prints well. This will also impact the post-processing time as there will be more material to clean off.

Longer Print Times

Imagine a 1 inch cube took about 10 minutes to print. Using the same settings, if that cube was made to be 2 inches, it would take (at a minimum) 8 times longer to print! The time that the nozzle would have to travel each side would double and the number of layers needed would double which would can be expressed mathematically as 2 x 2 x 2 = 8. Of course, settings can be changed to decrease infill, change layer heights, change the number of perimeters and solid, layers to help make these difference smaller, but the curve would follow the trend that as a print gets bigger, the longer it will take to complete. User are typically exposed to prints that are a few hours long on smaller printers, but on lager ones, print times can span days! That’s a major difference!

Potential of Running out of Filament

A lot of spools come in 1 lb or 1 kg quantities. This is sufficient for small prints, but can be consumed on the first few layers of a larger print! The largest spools we stock at re:3D are 15 lbs. These massive amounts of filament allow us to print very large items without much thought with regards to running out of filament. It still does happen however, and it is one of the things that must be considered when starting a multi-day print. Since our software does allow for filament change-out, it is not a big ordeal to swap filament mid-print, but it does slow down the production process, and it needs to be planned for. As prints go into ever-longer territory, the potential for running out of filament is one of the manufacturing spaces that must be considered.

Ernie travels w/Gigabot to share his insights at SXSW, the Austin Mini Makerfaire and UBM Minnesota

We’ve explored some of the benefits and considerations of 3D printing large objects. While the list is by no means exhaustive, it does provide an insight into some the areas where new learning is required and it definitely showcases the great possibilities that are unlocked by an expanded creative volume. Hopefully this provides some insight on what is involved with large prints and we’d be happy to hear your feedback and answer any questions.

Catch you on the next layer!

~Type 1 Ernie: re:3D Ops Man

Ernie Prado

Blog Post Author

Material Testing & Heat Treating Natureworks PLA 3D850

The notes below reflect our new open-source filament testing protocol. After evaluating the printability of Coex PLA Prime/PLA 3D850 on Gigabot, I decided to experiment with a heat treatment process.  

Manufacturer:  Coex    

Filament Name:  PLA Prime

Color Tested:  Natural

Date Received: 6/10/2016

Date Tested: 6/16/2016

Ease of use:   Excellent

Appearance:  Clearer than regular PLA

Size consistency: Great

Color consistency: Great

Odor: None

Manufacturer’s recommendations

  • Speed: none given mm/s
  • Temperature: has a higher MFI so should be able to print slightly cooler than regular PLA C
  • Infill %: any
  • Layer Height: tested at 0.3175mm
  • Printer Used: GB # 004
  • Print temperature used: 200 C (nozzle) /55C (bed)
  • Speed used: 60 mm/s
  • Layer Height:0.3175 mm
  • Infill: 15%
  • Odor: none
  • Type(s) of print surface used: Print n Z

FINDINGS

Bed adhesion (1: terrible-5: fabulous!)

   5

Stringing (1: lots -5: none!)

   4

Shrinkage (1: lots-5: none!)

   4: None!

Interlayer adhesion (1: terrible-5: fabulous!)

   4: Perfect!

The technical datasheet for the pellets that the filament is derived from can be found here.

I suspect that most, if not all the temperature resistant PLA uses the 3D850 as its base. There is very little information out there for recommended heat treat methods.

Here are a couple pictures from a recent experiment I did with Natureworks PLA 3D850 that claims increased crystallization with heat treat. I used a wall oven to heat treat the parts at 200F but please note that I did not verify with a second thermometer.

The three parts on the top row are not heat treated and the three on the bottom row are heat treated at 200F for 15 minutes. I placed the parts into a cold oven and let the oven heat to temp and maintained temp for 15 minutes then removed the parts to air cool. The color change and warping happened while the parts were in the oven not after they were removed.The top two parts were made with one perimeter (0.48mm width). The center two are two perimeters and the bottom two have three perimeters. Interestingly enough the part with two perimeters warped the least. I also heat treated a couple objects with more structural integrity and found little to no warping (small 5″ Moai statue and the re3D logo placard).

I think the next steps are to control the rate of heating to see if the amount of warping can be reduced. Would love to hear other’s experience with heat treating the PLA 3D850.

Further information about annealing PLA is here: http://www.4spepro.org/view.php?article=005392-2014-03-28
 
Quesions or Comments?
  • Share your thoughts on the materials section of our forum:
    • https://re3d.zendesk.com/hc/en-us/community/posts/206087383-Natureworks-3D850
 
Happy Printing!

Matthew Fiedler

Blog Post Author

How My Gigabot Fixed the Power Wagon

One of the realities of owning an old car is that they tend to wear out with time. In my case I am the fortunate owner of a 1949 Dodge Power Wagon that was originally purchased new by my grandfather Leo.

It happened last week when I first started the engine that I smelled the unmistakable odor of leaking fuel. Upon a little investigation I found the fuel bowl gasket had given up it’s ghost and was no longer providing an effective seal between the fuel pump and the sediment bowl. After calling a few automotive parts stores it quickly became evident that parts for a 1949 Dodge were not kept in stock.
 
Lucky for me and my normally trusty Power Wagon I have a Gigabot 3D printer and a stock of TPU filament from Fenner drives (https://ninjatek.com/) that I hoped to use for manufacturing a suitable replacement fuel gasket. A quick investigation of the chemical resistance for the TPU filament showed an “A” resistance to gasoline and I quickly set off to create the CAD model for the simple gasket. A few minutes later I had the Model processed for 3D printing using Simplify3D and was pressing the Print button on Gigabot.

The gasket was printed in under five minutes and I felt a great sense of accomplishment as I installed the gasket and started the old truck. No more leaking fuel and just for safe measure in another five minutes I had made myself a spare!

~Happy Printing

Matthew Fiedler

Blog Post Author

Making a 3D Printed Bicycle Prototype

Last summer, Patrick Fiedler developed a 3D printed bicycle prototype for his summer internship.  In his own words, he describes his design process:

Have you ever wondered how 3D printing, renewable resources, and transportation all fit together? Although there many possible combinations, one instance is the 3D printed bicycle project that I worked on last summer. I had the wonderful opportunity to intern at re:3D in Houston, Texas and got the chance to work on this awesome project with the intention of answering this question: Is it possible to 3D print a working bicycle? I set out to do just that. With the large format possibilities of the Gigabot and wide range of filaments compatible with the Gigabot’s re3D hot end, I had the means to get started answering this question. The following is a brief review of my project that I wanted to share with the 3D printing community.

First, I deconstructed a MGX bicycle I found laying around. I analyzed its components and assembly mechanics thoroughly. I had to decide what could possibly be replaced with customized 3D printed components. The most likely option was the frame. With the customizability that comes with any 3D printed piece, I could easily use the modular nature of bicycle parts to attach them to my frame and roll from there (hopefully literally).

I set out to choose a good filament for frame construction. Thankfully, I had already been making ASTM tensile test samples for research re:3D was doing with Dr. Scott Fish at the University of Texas at Austin. Some of the most common filaments: ABS and PET tend to be brittle so it would not be ideal for a bicycle that experiences many dynamic forces and needs the ductility to flex as well as strength. I settled on Taulman 910 filament which combined the durability/elongation of nylon and the strength of co-polymers.

I printed a couple tubes with Taulman’s 645 Nylon filament which seemed pretty strong and had the ability to bend by hand without cracking. However, I realized that a 3D printed tube is much more expensive than metal, and there might be a better material to do the job. I need look no further than outside my bedroom window where a grove of bamboo plants grew flourishing in the humid hot Houston summer. Bamboo grows so fast and is so strong that it would make a perfect renewable tube for the bicycle. I set to work chopping down some plants and then trying various forms of heat treatment from a blow torch, to the oven. A few burnt ends and one smoky kitchen later, I had (somewhat) dry tubes to work with. For those intending to work with bamboo, I suggest either letting them air dry in a dry place out of the sun or at very low temps in an oven with no part of the bamboo touching the oven sides.

To connect these tubes, I used the Taulman 910 to create modular connector pieces. The pieces were custom printed with receiving holes for the diameter of the bamboo pieces I had cut earlier. The nice thing about 3D printing these parts is that you can conform to the exact geometry of your bicycle dimensions and the tubes you decide on using. Using the Simplify 3D program, I was able to examine my layers to make sure the path of my support structure would work out alright. The connector piece shown here is the bottom bracket where the pedal cranks, down tube, seat tube, and chainstays connect.

Interfacing with the rest of the components was the next challenge. The bicycle wheels clamped onto fork shaped dropouts which were easy enough to print. The real fun was going to be putting the crank arm bearings and the headset on. I decided to try a press fit approach for the crank bearings. The 910 was ductile enough to press those bearing right in there. Nothing to block rotation. In addition, I found out that you can machine 910 prints. The headset nuts have threads on the internal diameter that needed to thread onto the frame. I threw some of my 3D printed tubes on the lathe, turned them down, and added some threads. It worked much better than expected. Just remember to make your wall thickness large enough so that you don’t machine into the infill.

The bamboo tubes, the 3D printed tubes and connector pieces all slid together nicely with only a minor fit problem. I forgot support structure on one of my rear dropouts, thus I heated it in some hot water to make it malleable enough to bend back into the proper shape. Everything was adhered together with a two part epoxy and held in place by my bungee cord fixture.

The end product looks much like a real bicycle and may have had the chance to ride like one. A few technical problems kept this prototype from being fully functional. There was some interference along the chain path to prevent usage of some of the gears. Also, the 3D printed tube that runs through the headset above the front fork failed under the large moment that is created by the front fork acting as a lever arm. The rest of the frame, however, was very strong and was able to support weight.

At the end of my time in Houston, I was very surprised at how far the bicycle was able to come along thanks to the structural properties of the Taulman 910 as well as the large format printing capabilities of the Gigabot. If I were to do it again, I would use as much bamboo as possible so it could be renewable. I would also focus on how little plastic material would be needed to make strong connectors, possibly experimenting with more renewable filaments such as PET despite its limitations. Although it wasn’t completely functional, I am confident that yes, it is possible to create a working 3D printed bicycle. One aspect I did like about the modular design was its ability to conform to the exact dimensions needed. All that would be needed would be to change a couple of angles and bamboo tubes lengths, and you would have the geometry for any human rider. You could have a bicycle custom fit to you without needing to settle on a typical configuration. In addition, I liked how easy it was to put together. Anyone with a 3D printer, a bamboo conducive climate, and a nearby bicycle parts repository (like the Austin Yellow Bike Project) Keep your eyes open as I have seen others who are working on their own 3D printed bicycles as well.

All in all, this project was a large amount of fun and made for an amazing summer with the Gigabot 3D printer!

Happy Printing!

Patrick Fiedler

Blog Post Author

Want to continue the research? Apply for an internship at re3d.org/careers!